Heavy oil extraction system

ABSTRACT

An efficient high-temperature water vapor generator is used to heat heavy oil located in an underground cavity, thereby reducing the viscosity of the oil and enabling the oil to be pumped to the surface. The vapor generator includes a combustion chamber and a surrounding structure, wherein a cavity is located therebetween. Water is routed through the cavity and into the combustion chamber, where water vapor and heat are generated in the presence of fuel, ignition and air. The generated heat pre-heats the water in the cavity, thereby creating an efficient system. The water vapor is forced into the underground cavity, thereby heating the oil located in the cavity.

RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 10/686,097, filed Oct. 14, 2003 now U.S. Pat. No.7,228,822, entitled “Environmental Clean-Up System”, by Aldon R.Reinhardt.

FIELD OF THE INVENTION

The present invention relates to an electrical generation system thatoperates in response to a vapor generator.

BACKGROUND OF THE INVENTION

Soil pollution is becoming a significant problem in this country. Innumerous locations around the country, hazardous wastes, such as MTBE's,volatile organic compounds (VOCs), poisons and other chemicals have beeninadvertently released, thereby contaminating the surrounding soil. Suchsoil contamination can be caused, for example, by leaking undergroundstorage tank sites (LUST sites). The hazardous waste may leak throughthe soil, eventually contaminating water supplies.

Cleaning up contaminated soil is both difficult and costly. Typically,the owner of a site containing contaminated soil is responsible for thissoil. However, because there is no cost effective manner of cleaning thesoil, the owners of contaminated soil typically pay to have the soilremoved and stored at a remote location. One such location is theKettleman Hazardous Waste Landfill, located near Fresno, Calif. The costfor removing and storing contaminated soil is typically about $65/cubicyard.

It would therefore be desirable to have a cost efficient method andapparatus for cleaning contaminated soil. It would further be desirableif this method and apparatus were portable, such that contaminated soilcould be de-contaminated on-site, without requiring that thecontaminated soil be transported a significant distance.

In addition, it would be desirable to have a vapor generator capable ofefficiently generating high-temperature water vapor for a multitude ofuses including, but not limited to: de-contamination, in-situ heating ofoil reserves to facilitate pumping, food preparation, cleaning anddisinfecting, snow and ice removal, desalinization of sea water,generation of electricity, drying and curing, space heating andhumidification, and the conversion of organic waste to other products.

SUMMARY

Accordingly, the present invention provides an efficienthigh-temperature water vapor generator, which can be used tode-contaminate soil, and for many other applications. The vaporgenerator includes a generally cylindrical combustion chamber and asurrounding structure, wherein a cavity is located between thecombustion chamber and the surrounding structure. Water is routedthrough the cavity and into the combustion chamber, where water vaporand heat are generated in the presence of fuel, ignition and air. Theheat generated inside the combustion chamber causes the water in thecavity to pre-heat. As a result, the water that is introduced to thecombustion chamber is pre-heated, thereby improving the efficiency ofthe water vapor generator.

The high-temperature water vapor is forced into a vapor tube, whichincludes openings for emitting the vapor. The vapor heats the heatingthe vapor tube to temperatures of 600° F. or greater. In one embodiment,the vapor tube is mounted in a horizontal configuration over a fixedplatform.

A cylindrical soil tube is supported such that this soil tube surroundsthe vapor tube. Contaminated soil in introduced to a first end of thesoil tube. The soil tube is rotated along its central axis by a driveassembly. Lifting paddles are located on the inner surface of the soiltube, thereby lifting the contaminated soil into contact with the vaportube. The soil is decontaminated by coming into contact with the hightemperature vapor tube. That is, hydrocarbons in the soil are cracked bythe high temperature. The lifting paddles move the soil toward thesecond end of the rotating soil tube, such that decontaminated soil isexpelled at the second end of the soil tube.

The decontamination process results in waste gases being emitted fromwithin the soil tube. In one embodiment, these waste gases are routedinto the vapor generator, thereby burning these waste gases andproviding a more efficient system.

The soil remediation unit of the present invention is compact, and caneasily be mounted on a truck bed, a trailer or a barge. Moreover, thevapor generator and drive assembly can be operated in response to one ormore portable batteries, a portable fuel supply and a portable (ornon-portable) water supply. Thus, the soil remediation unit can bebrought to the location where the contaminated soil resides. Because thesoil remediation unit decontaminates the soil on-site, there is no needto remove any contaminated soil to a remote location.

In accordance with another embodiment, the high-temperature water vaporprovided by the vapor generator can be routed into the ground, therebyheating heavy oil reserves located in the ground. Heating the oilreserves in this manner reduce the viscosity of the heavy oil, therebyenabling the oil to be easily pumped to the surface.

The present invention will be more fully understood in view of thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional diagram of a vapor generator in accordancewith one embodiment of the present invention.

FIG. 2 is a block diagram illustrating a vapor generating system thatuses the vapor generator of FIG. 1 in accordance with one embodiment ofthe present invention.

FIG. 3 is a schematic side view of a soil remediation system, which usesthe vapor generator system of FIG. 2 to de-contaminate soil inaccordance with one embodiment of the present invention.

FIG. 4 is a schematic top view of the soil remediation system of FIG. 3in accordance with one embodiment of the present inventions.

FIG. 5 is an end view of a portion of the soil remediation system ofFIG. 3 in accordance with one embodiment of the present invention.

FIG. 6 is a block diagram of an oil extraction system, which useshigh-temperature water vapor generated by the vapor generator system ofFIG. 2 to assist in the pumping of oil.

FIG. 7 is a block diagram of an electrical generating system, whichgenerates electricity in response to high-temperature water vaporgenerated by the vapor generator system of FIG. 2.

DETAILED DESCRIPTION

FIG. 1 is a cross sectional diagram that illustrates a vapor generator100 in accordance with one embodiment of the present invention. Vaporgenerator 100 is illustrated with an X-Y-Z coordinate system, asillustrated. Vapor generator 100 is generally cylindrical in nature,with the central axis of the cylinder parallel with the Z-axis.

Vapor generator 100 includes outer cylindrical section 101, innercylindrical section 102, a pair of inner conical structures 103-104, apair of outer conical structures 105-106, an air coupling element 107, avapor coupling element 108, an ignition coupling element 111, a fuelcoupling element 112, vapor baffle element 113, and water couplingelements 120-123.

In the described embodiment, the elements of vapor generator 100 aremade of 304-stainless steel. However, it is understood that vaporgenerator 100 can be made of other materials in other embodiments. Inthe described embodiment, vapor generator 100 has a height (H0) of about43¼ inches. Outer cylindrical section 101 is a tube having an outsidediameter of six inches and a height (H1) of 32 inches. The walls ofouter cylindrical section 101 have a thickness of 0.120 inches. Outerconical element 105 is connected to the upper end of outer cylindricalsection 101, and outer conical element 106 is connected to the lower endof outer cylindrical section. The ends of outer conical elements 105-106that are connected to the ends of outer cylindrical section 101 haveoutside diameters equal to 6 inches. The walls of outer conical elementshave a thickness of 0.120 inches. Thus, the ends of outer conicalelements 105-106 have the same dimensions as the ends of outercylindrical section 101. In accordance with one embodiment, the outerconical elements 105-106 are connected to the ends of outer cylindricalsection 101 by a conventional welding process. Each of the outer conicalelements 105-106 tapers down from a maximum diameter of 6 inches to aminimum diameter of 4 inches. Each of the outer conical elements 105-106has a height (H4) of about 4 inches along the Z-axis.

Inner cylindrical section 102 is a pipe having an outside diameter of 59/16 inches and a height (H2) of 30 inches. The walls of outercylindrical section 101 have a thickness of 0.40 inches. Inner conicalelement 103 is connected to the upper end of inner cylindrical section102, and inner conical element 104 is connected to the lower end ofinner cylindrical section 102. The ends of inner conical elements103-104 that are connected to the ends of inner cylindrical section 102have outside diameters equal to 5 inches. The walls of inner conicalelements 103-104 have a thickness of 0.40 inches. Thus, the ends ofinner conical elements 103-104 have the same dimensions as the ends ofinner cylindrical section 102. In accordance with one embodiment, theinner conical elements 103-104 are connected to the ends of innercylindrical section 102 by a conventional welding process. Each of theinner conical elements 103-104 tapers down from a maximum diameter of 5inches to a minimum diameter of 3 inches. Each of the inner conicalelements 103-104 has a height (H3) of about 5 inches along the Z-axis.

The smaller ends of inner conical element 103 and outer conical element105 are connected to air coupling element 107. In the describedembodiment, the smaller ends of inner conical element 103 and outerconical element 105 are welded to the underside of the cylindrical aircoupling element 107, such that these conical elements areconcentrically located around a central axis (which is parallel with theZ-axis). In the described embodiment, air coupling element 107 is acylindrical element having an inside diameter of 3 inches, an outsidediameter of 4.5 inches, and a height (H5) of about 1⅝ inches. Asdescribed in more detail below, the opening of air coupling element 107is subsequently configured to receive an inflow of air.

Vapor baffle 113 is also connected to the lower surface of air couplingelement 107. In the described embodiment, vapor baffle 113 is a pipehaving an inside diameter of 3 inches, a wall thickness of about 0.118inches, and a height (H8) of about 4 inches (along the Z-axis). Thebottom edge of this pipe has a flange that extends outward from thecentral axis of the pipe. In the described embodiment, this flange hasan outer diameter of about 5 inches. As described in more detail below,vapor baffle 113 regulates the flow of gasses within vapor generator100.

The smaller ends of inner conical element 104 and outer conical element106 are connected to vapor coupling element 108 in the same manner thatinner conical element 103 and outer conical element 105 are connected toair coupling element 107. In the described embodiment, vapor couplingelement 108 is identical to air coupling element 107. As described inmore detail below, the opening of vapor coupling element 108 issubsequently configured to provide an outflow of heated water vapor.

A cavity 131 is formed between the inner conical elements 103-104/innercylindrical element 102 and the outer conical elements 105-106/outercylindrical element 101. As described in more detail, this cavity 131 isused to store (and pre-heat) water during normal operating conditions ofvapor generator 100. Cavity 131 is capable of storing approximately 200gallons of water.

A combustion chamber 130 is defined by inner conical elements 103-104,inner cylindrical element 102, air coupling element 107 and vaporcoupling element 108. As described in more detail below, a fuel/airmixture is ignited in the combustion chamber 130, thereby heating waterthat has been injected into the combustion chamber 130.

Ignition coupling element 111 is a cylindrical element that extendsthrough inner and outer conical elements 103 and 105, as illustrated. Inthe described embodiment, ignition coupling element 111 has an outsidediameter of 1 inch, an inside diameter of 14 mm, and a length of 1⅛inches. The cylindrical opening through ignition coupling element 111 isthreaded for receiving an ignition element (e.g., a spark plug). Asdescribed in more detail below, the ignition element introduces sparkingwithin combustion chamber 130. The opening of ignition coupling element111 is located about 2 inches below the lower surface of air couplingelement 107.

Fuel coupling element 112 is also a cylindrical element that extendsthrough inner and outer conical elements 103 and 105, as illustrated. Inthe described embodiment, fuel coupling element 112 has an outsidediameter of ⅜ inches, an inside diameter of 5/16 inches and a length ofabout 1¼ inches. The cylindrical opening through fuel coupling element112 is configured to receive a fuel line. The opening of fuel couplingelement 112 is located about 2 inches below the lower surface of aircoupling element 107. As described in more detail below, a fuel, such aspropane or natural gas, is introduced to combustion chamber 130 via fuelcoupling element 112. This fuel is ignited by sparks provided by theignition element. As described in more detail below, vapor baffle 113helps to contain the fuel in the same general vicinity as the ignitionelement, thereby improving the burn of the fuel.

Water coupling elements 120-123 are also cylindrical elements. In thedescribed embodiment, these elements 120-123 each have an outer diameterof 1 inch, an inner diameter of ½ inches. Water coupling element 120,which has a length of about 1½ inches, extends through both outercylindrical section 101 and inner cylindrical section 102. As describedin more detail below, water coupling element 120 is configured toreceive a water injection device, such that water can be injected intoinner chamber 130. Water coupling elements 121-123, each of which has alength of about 1½ inches, extends through outer cylindrical section 101(but not through inner cylindrical section 102). The central axes ofwater coupling elements 121-122 are located at a height (H6) of about 1½inches above the lower edge of outer cylindrical section 101. Thecentral axes of water coupling elements 120 and 123 are located at adistance (H7) of about 2½ inches below the upper edge of outercylindrical section 101.

As described in more detail below, water is introduced into cavity 131via water coupling element 123. The water level in cavity 131 ismaintained at a level that is higher than water coupling element 123. Asdescribed in more detail below, water is removed from cavity 131 via oneor more of the water coupling elements 121 and 122.

Although vapor generator 100 has been described with particulardimensions and shapes, it is understood that other dimensions and shapescan be used in other embodiments.

FIG. 2 is a block diagram illustrating a vapor generating system 200that uses vapor generator 100 in accordance with one embodiment of thepresent invention. In addition to vapor generator 100, system 200includes air supply line 201, blower 202, ignition element 211, ignitioncontroller 212, fuel supply line 221, fuel supply 222, water supplylines 230-231, water supply 232, water injector 233, pre-heated watersupply line 234, water plug 235, water pump/regulator 236 and vaporexhaust line 241.

In general, system 200 operates as follows to produce high temperaturesteam (vapor). As described in more detail below, this high temperaturevapor is subsequently used to decontaminate a material, such as soil, orto heat heavy oil deposits located underground. Air, water, fuel andsparks are introduced to vapor generator 100 by air blower 202, waterinjector 233, fuel supply 222 and ignition element 211, respectively.The sparks ignite the fuel and air to heat the injected water. Inresponse, vapor generator 100 generates super-heated steam (vapor)having a temperature of about 400 to 1000° F. The high temperature watervapor is forced out through vapor exhaust line 241. As described in moredetail below, exhaust line 241 carries the high temperature water vaporto a soil moving device or an underground oil reserve. The hightemperature water vapor is then used to remove contaminants from soilthat is forced through the soil moving device. Alternately, the hightemperature water vapor is used to heat underground oil reserves,thereby reducing the viscosity of the underground oil and enabling thisoil to be pumped to the surface.

In the described embodiment, air supply line 201 is flexible aluminumtubing having an inside diameter of 3 inches and a length of about 20inches. Other lengths and diameters can be used in other embodiments.Air supply line 201 can be coupled to air coupling element by a clamp.When air blower 202 is turned on, air is forced through air supply line201 and into combustion chamber 130. In the described embodiment, airblower 202 is a 10 horsepower (hp) high-speed hydraulic motor availablefrom Spencer Industries, as part number EAT104-1006-006. This hydraulicmotor is capable of operating at about 2000 rpm in response to a 24 Voltsupply battery. In the described embodiment, air blower 202 provides anair flow in the range of about 200 to 700 cubic feet per minute (cfpm)at a maximum pressure in the range of about 2 to 5 pounds/square inch(psi). Other air blowers can be used in other embodiments of the presentinvention.

In the described embodiment, both fuel coupling element 112 and fuelsupply line 221 have an inside diameter of about ⅜ inch. Fuel supplyline 221, which is made of stainless steel, is coupled to fuel couplingelement with a conventional metal sealed connector. Fuel supply 222 iscontrolled to provide a flow of fuel through fuel supply line 221 andfuel coupling element 112 into combustion chamber 130. In the describedembodiment, the fuel supply 222 is a 100-gallon fuel tank containingeither propane or natural gas. Fuel supply 222 can be controlledmanually or automatically in various embodiments of the presentinvention. The maximum fuel flow into combustion chamber 130 is on theorder of 40 to 80 standard cubic feet per hour (scfh). In oneembodiment, the fuel flow is about 2 gallons per hour, for a daily (8hour) fuel cost of about $20. In the described embodiment, a controlvalve is inserted into fuel coupling element 112, thereby limiting thefuel pressure to about 8 psi.

In the described embodiment, ignition element 211 is located at the sameheight as fuel coupling element 112, with a 180 degree separationbetween ignition element 211 and fuel coupling element 112. Ignitionelement 211 can be, for example, a spark plug available from Bosch aspart number W6DC. Other spark plugs can be used in other embodiments.Ignition controller 212 transmits electrical control signals to ignitionelement 211. These electrical control signals are selected such thatignition element 211 fires (sparks) continuously while these electriccontrol signals are being transmitted. Continuously firing ignitionelement 211 advantageously prevents the accumulation of combustionproducts on the surfaces of ignition element 211. The electrodes ofignition element 211 are located inside of combustion chamber 130, suchthat the sparks are created within combustion chamber 130. The expectedlife of ignition element 211 under these conditions is on the order ofabout 5000 hours. In the described embodiment, ignition controller 212is a spark generator available from Dongan Electric ManufacturingCompany as part number A06SAG. Ignition controller 212 is capable ofoperating in response to a 24 Volt battery supply.

Water supply line 230 couples water supply 232 to water pump/regulator236. In response, water pump/regulator 236 provides a controlled flow ofwater to water supply line 231 and water coupling element 123. Waterpump/regulator 236 can be, for example, product number PA38IN availablefrom The Berns Corporation, which is a water pump capable of providing amaximum flow of 10 gallons per minute (GPM) at a pressure up to 240 PSI.In another embodiment, water pump/regulator 236 can be obtained fromShurflo as part number 52063-B979. In the described embodiment, watersupply lines 230-231 are made of rubber hose having an inside diameterof about 1 inch. Water supply line 231 is coupled to water couplingelement 123 by a ½ inch pipe nipple. In one embodiment, a ⅜ inch Nuproball valve is included in water coupling element 123.

Water pump/regulator 236 pumps water into cavity 131 at a controlledpressure. In the described embodiment, water is pumped into cavity 131at a pressure of about 70 psi. Water pump/regulator 236 advantageouslyenables a constant, controllable water flow to be provided, regardlessof the characteristics of water supply 232. In the described embodiment,water coupling element 122 is sealed by plug 235. In this embodimentwater coupling element 122 provides redundancy, in case water couplingelement 121 is (or becomes) defective. The water level 226 within cavity131 is controlled such that this water level 226 is higher than watercoupling element 123. In a particular embodiment, water level 226 iscontrolled such that cavity 131 is substantially full during normaloperation of system 200.

The water in cavity 131 is heated due to the proximity to combustionchamber 130. That is, heat from the combustion chamber 130 heats thewater in cavity 131 via the thermally conductive inner cylindricalsection 102 and inner conical structures 103-104. In one embodiment, thewater in cavity 131 is heated to a temperature of about 60 to 212° F.Water pump/regulator 236 forces the heated water to exit cavity 131 andenter pre-heated water supply line 234, near the lower end of thecombustion chamber 130. Pre-heated water supply line 234, whichwithstand the heat of the pre-heated water, can be, for example, metaltubing. From pre-heated water supply line 234, the heated water enterswater injection element 233. In response, water injection element 233causes the heated water to enter combustion chamber 130 as a spray. Inthe described embodiment, water injection element 233 injects water at arate of 2 to 5 gallons/minute (gpm). Water injection element 233 can be,for example, part number 137-155, available from Delaven. In accordancewith the present embodiment, water is introduced to the upper end ofcavity 130 through water coupling element 123 and extracted from thelower end of cavity 130 through water coupling element 121. Thisconfiguration helps to ensure that water, and not steam, flows fromcavity 131 to pre-heated water supply line 234. Note that any steamforming in cavity 131 will collect near the upper end of cavity 131.Thus, it may be difficult to extract water at the upper end of cavity131.

Within combustion chamber 130, the sparks introduced by ignition element211 ignite the fuel introduced by fuel supply 222 and the air introducedby blower 202, thereby generating heat, which in turn, causes thepre-heated water introduced by water injection element 233 to becomesuper-heated. Air blower 202 forces the burnt fuel/water mixture(hereinafter referred to as the “vapor”) toward the bottom of combustionchamber 130. The vapor pressure is increased as the combustion chamber130 narrows.

Locating ignition element 211 and fuel coupling element 221 near the topof the combustion chamber 130 advantageously allows a long time for thefuel to burn. That is, the fuel is allowed to burn down the entirelength of the combustion chamber 130. This allows the fuel to burncompletely. The length of the combustion chamber 130 is selected to belong enough to allow the fuel to burn completely. The pre-heated wateris also introduced near the top of the combustion chamber 130, therebyallowing this water to be heated along the entire length of thecombustion chamber 130, such that the pre-heated water is completelyconverted to heated water vapor.

The force introduced by air blower 202 further causes the vapor to flowthrough vapor supply line 241. The vapor in vapor supply line 241 has atemperature in the range of about 200 to 1400° F. and a pressure in therange of about ½ to 5 psi. In one embodiment, vapor supply line 241 isstainless steel tubing, having a diameter of about 2 inches. The exhaustprovided at vapor supply line 241 is relatively clean. It is estimatedthat the vapor will consist of about: 20% water vapor, 5% CO, 10% O₂,63% CO₂ and 2% NO.

In accordance with one embodiment, system 200 is started as follows.First, air blower 202 and ignition controller 212 are turned on. As aresult, any residual fuel in combustion chamber 130 will be safely burntand blown out of vapor supply line 241. About ten seconds later, fuelsupply 222 is turned on, thereby providing fuel flow to combustionchamber 130. At this time, fuel begins burning, thereby pre-heatingcombustion chamber 130. About ten seconds after fuel supply 222 isturned on, water pump/regulator 236 is turned on, thereby introducingwater to combustion chamber 130. Vapor is then generated in combustionchamber 130 in the manner described above.

In accordance with another embodiment, system 200 is turned off byturning off fuel supply 222, ignition controller 212 and water supply232 at about the same time. Blower 202 is allowed to run for about 30seconds longer, thereby clearing combustion chamber 130 and vapor supplyline 241.

FIG. 3 is a schematic side view of a soil remediation system 300, whichuses vapor generator system 200 to de-contaminate soil in accordancewith one embodiment of the present invention. FIG. 4 is a schematic topview of soil remediation system 300. Note that vapor generator system200 is not shown in FIG. 4 for reasons of clarity. Soil remediationsystem 300 includes a base assembly 301, which is formed from steel. Inthe described embodiment, base assembly 301 has a height of about 4inches, a length of about 276 inches and a width of about 40 inches.Base assembly 301 is supported by ten support legs, including supportlegs 302-306. Note that five support legs (not shown) are hidden behindsupport legs 302-306 in the side view of FIG. 3. Each support leg ismade of steel. In the described embodiment, each of the support legs hasa height of about 18 inches and a square cross section of about 4 inchesby 4 inches. The support legs are welded to base assembly 301.

The support legs are also welded to an underlying platform 307. In thedescribed embodiment, platform 307 is the bed of a large truck ortrailer. In the described embodiment, platform 307 is supported by fouror more wheels of the truck/trailer, including wheels 308-309, byconventional means. Note that two wheels (not shown) are hidden behindwheels 308-309 in the side view of FIG. 3. In other embodiments,platform 307 can be a raised stationary structure.

System 300 further includes a front support assembly 311 and a rearsupport assembly 312, each having an L-shaped cross section. The basesof front and rear support assemblies 311-312 are bolted down to baseassembly 301. In the described embodiment, front and rear supportassemblies 311-312 are made of steel having a thickness of about 1 inch.The bases of front and rear support assemblies 311-312 each have alength of about 8 inches and a width of about 36 inches. Front supportassembly 311 has a height of about 57½ inches, and rear support assembly312 has a height of about 31 inches. An inner tube rear support 314 iswelded to rear support assembly 312 as illustrated. Inner tube rearsupport 314 is a cylindrical steel tube having a length of about 18inches, and an outside diameter of about 3½ inches.

A vapor tube 313 extends between, and is supported by, front and rearsupport assemblies 311-312. A first end of vapor tube 313 extendsthrough an opening in front support assembly 311. In one embodiment, thefirst end of vapor tube 313 is welded in this opening. The first end ofvapor tube 313 is open. As described in more detail below, this openingin vapor tube 313 is coupled to receive the high temperature vaporprovided by vapor generator 100.

The second end of vapor tube 313 fitted over inner tube support assembly314, as illustrated. As a result, inner tube support assembly 314supports the second end of vapor tube 313. The second end of vapor tube313 is welded to rear support assembly 312. As a result, the second endof vapor tube 313 is effectively sealed. In the described embodiment,vapor tube 313 is schedule 40 type 347 stainless steel cylindrical tube,having a 4 inch outside diameter, a wall thickness of 0.237 inches, anda length of 216¼ inches. In other embodiments, vapor tube 313 can haveother shapes. For example, vapor tube 313 can have a triangular crosssection, with a vertex of the vapor tube pointing straight up.

A plurality of vapor openings 315 extend through a sidewall of vaportube 313. These vapor openings 315 are located along the length of vaportube 313. In a particular embodiment, these vapor openings 315 are alllocated along a straight line that extends along the length of vaportube 313. Vapor tube 313 is positioned such that these vapor openings315 are located on the underside of vapor tube 313. In the describedembodiment, there are about 29 vapor openings located on the undersideof vapor tube 313, each having a diameter of about ⅜ inches. Asdescribed in more detail below, the high temperature vapor from vaporgenerating system 200 enters the first end of vapor tube 313 and exitsthrough vapor openings 315. The high temperature vapor heats vapor tube313 to a temperature that is sufficiently high to remove contaminantsfrom soil.

A drive assembly 331 and an idler assembly 332 are also mounted on baseassembly 301. Drive assembly 331 and idler assembly 332 support a mainauger assembly 320, which surrounds, but does not contact, vapor tube313. Main auger assembly 320 includes wear cylinders 321-322, gearelement 323, soil tube 324, and internally located lift paddles 1-4. Inthe described embodiment, soil tube 324 is a schedule 40 C/S pipe havingan outside diameter of 20 inches and a length of 216 inches. In otherembodiments, soil tube 324 can have other dimensions. For example, soiltubes having diameters of 30 or 40 inches can be used to provide moresoil throughput. The location of soil tube 324 is maintained by gearelement 323, which engages a corresponding gear element 333 on driveassembly 331. Soil tube 324 is positioned such that a ½ inch clearanceis maintained between a first end of soil tube 324 and front supportassembly 311.

During normal operation, soil tube 324 is rotated along its centralaxis, around the stationary vapor tube 313. This rotation is facilitatedby drive assembly 331, idler assembly 332 and motor 337. As shown inFIG. 4, drive assembly 331 includes a rotating drive element 335 and arotating support element 336. Rotating drive element 335 includes twowear rings 401-402, which contact wear ring 321, and a recessed gearelement 333, which engages raised gear element 323. Rotating supportelement 336 includes wear rings 411-412, which contact wear ring 321,and a recessed channel 413, which is located between wear rings 411-412.Recessed channel 413 receives, but does not contact gear element 323. Inthe described embodiment, wear rings 401-402 and 411-412 are made of thesame material as wear ring 323.

Idler assembly 332 includes a first rotating idler assembly 421 and asecond rotating idler assembly 422. The first rotating idler assembly422 includes a first rotating wear ring 431, which contacts wear ring322. The second rotating idler assembly 422 includes a second rotatingwear ring 432, which contacts wear ring 322. The first and secondrotating wear rings 431-432 rotate about a pair of corresponding axles,which are supported by a corresponding pair of brackets, which areconnected to base assembly 301.

FIG. 5 is an end view of wear ring 321, gear element 323 and driveassembly 331. Note that gear element 323 extends above wear ring 321. Inthe described embodiment, gear element 323 has a height of 24 inches anda width of 1⅛ inches. In the described embodiment, gear element 323 isformed by one or more laser cut pieces of A36 steel, which are welded towear ring 321. As described above, gear element 333 is slightly recessedwith respect to wear rings 401-402, such that gear element 333 engageswith gear element 323, and wear rings 401-402 contact wear ring 321.Also, as described above, wear rings 411-412 contact wear ring 321, butgear 323 does not contact assembly 201 within channel 413. Both rotatingdrive element 335 and rotating support element 336 are suspended byaxles that are supported by brackets that are mounted on base assembly301. Both rotating drive element 335 and rotating support element 336are free to rotate about their central axes. The drive shaft of motor337 is attached to a coupling element 334, thereby enabling motor 337 toturn rotating drive element 335 of drive assembly 331. Rotating driveelement 335 thereby rotates main auger assembly 320 via gear elements333 and 323. In the described embodiment, motor 337 is a 10 hp hydraulicmotor capable of turning main auger assembly 320 at a rate of 0-10rotations per minute (rpm). In the described example, motor 337 is partnumber EAT104-1006-006, available from Spencer Industries.

Idler assembly 332 supports main auger assembly 301 as the main augerassembly is rotated. More specifically, wear ring 322 rotates on firstrotating wear ring 431 and second rotating wear ring 432. In thedescribed embodiment, each of wear rings 431-432 has an outside diameterof 21 inches. Wear ring 322 rests on wear rings 431-432. Wear ring 322rotates freely on wear rings 431-432, thereby enabling the entire augerassembly 320 to rotate in response to motor 337. Wear rings 321-322 and431-432 are made of a material that is more resistant to wear than soiltube 324. For example, wear rings 321-322 and 431-432 can be made of A36steel having a thickness of ½ inch.

A soil feed chute 341 is attached to front support element 311. Chute341 includes an upper opening for receiving contaminated soil, and alower opening for feeding contaminated soil through front supportelement 311 into tube 324. The contaminated soil can be loaded into theupper opening of chute 341 in a controlled manner by various means,including a conveyor belt 351.

A set of four lifting paddles 1-4 are located inside soil tube 324. Theends of these lifting paddles 1-4 are shown in FIG. 5. Lifting paddles1-4 have angled ends, which help to hold soil as the soil tube isrotated. The direction of rotation, R, is illustrated in FIG. 5. Liftingpaddles 1-4 each follow a spiral pattern along the length of soil tube324. This spiral pattern is shown schematically by line 325 in FIG. 3.Note that the lifting paddles maintain a spacing of about 90 degreesthroughout this spiral pattern. This spiral pattern helps to move soilfrom the first end of soil tube 324 to the second end of soil tube 324,as soil tube 324 is rotated. Lifting paddles 1-4 also cause thecontaminated soil to be lifted over, and then dropped down upon, vaportube 313. As a result, the soil does not clog the vapor openings 315 invapor tube 313. As described in more detail below, vapor tube 313 isheated to a temperature of about 500 to 1200° F. by vapor produced byvapor generator 100. When the contaminated soil comes into contact withvapor tube 313, the hydrocarbons and volatile organic compounds (VOC's)present in the contaminated soil are cracked, thereby eliminating thehydrocarbons, and providing one or more by-product gasses. The hightemperature vapor tube 313 also eliminates other contaminants from thesoil, such as mercury.

Decontaminated soil exits the second end of soil tube 324, and fallsthrough exit chute 342, which extends through base assembly 301 andplatform 307. The decontaminated soil can then be removed, for example,by a conveyor belt assembly 352.

In accordance with one embodiment, a cover 360 extends over main augerassembly 320, as illustrated in FIG. 3. This cover 360 is used tocollect the gases that are expelled from soil tube 324. These gasesinclude water vapor that is expelled through the holes 315 in the bottomof vapor tube 313. These gases also include the by-product gases createdby decontaminating the soil. The air supply line 201 of vapor generator100 is attached to cover 360, such that air blower 202 pulls in airpresent under cover 360. As a result, remaining contaminants in theby-product gases are burned when returned to vapor generator 100.

In the foregoing manner, the soil remediation system 300 is capable ofefficiently cleaning contaminated soil. Soil remediation system 300 caneasily be moved to job sites, thereby eliminating the need to transportcontaminated soil over long distances. Soil remediation system 300 canadvantageously be run in remote locations, because the motor 337, blower202, ignition control unit 212 all run from battery power, fuel supply222 can be provided in portable tanks, and water is either readilyavailable or can be provided by portable tanks.

The various embodiments of the structures and methods of this inventionthat are described above are illustrative only of the principles of thisinvention and are not intended to limit the scope of the invention tothe particular embodiments described. For example, although soil tube324 has been described as having a horizontal arrangement, it isunderstood that one end of soil tube 324 may be elevated with respect tothe other end.

In addition, although the vapor generator 100 has been described inconnection with the application of soil remediation, it is understoodthat vapor generator 100 can be used in many other applications inaccordance with other embodiments of the present invention. Some ofthese other applications are described below. Other applications wouldbe apparent to one of ordinary skill in the art.

Oil Industry Applications

Currently there are oil fields where the natural viscosity of the oil isgreater than the current ability to pump the oil to the surface. Thisoil is hereinafter referred to as ‘heavy oil’. In these cases, the heavyoil and or heavy oil field is heated to reduce the viscosity of the oil,thereby enabling pumping. Currently the source of heat is steam and/orhot water. The cost of heating the steam or hot water is the largestoperational cost in the production of the retrieval of the heavy oil. Ingeneral, a large high-pressure boiler is used to generate steam at acentral location. The steam is then routed from the high-pressure boilerto the various heavy oil wells using a network of distribution pipes.The steam must travel over undesirably long distances to reach thevarious heavy oil wells, thereby resulting in inefficient heat transfer.In addition, a water treatment plant is typically required to improvethe quality of the water provided to the boiler. Much of the heavy oilreserves in the world are currently untapped because it is economicallyprohibitive to remove the oil from the ground.

In accordance with another embodiment of the present invention, each oilwell site can be configured to receive the steam generated by acorresponding on-site vapor generator system 200. FIG. 6 is a blockdiagram of an oil well site 600 having a corresponding on-site vaporgenerator system 200. In this embodiment, vapor generator system 200provides vapor into an opening 603 in the ground 602 which leads to anunderground cavity 604 that contains heavy oil 605. The vapor heats theheavy oil 605, thereby resulting in lower viscosity oil that can bepumped out of the ground by an oil pump 601. Note that oil pump 601 mayuse the same opening or a different opening than vapor generator system200.

In the illustrated embodiment, the large high-pressure boiler, watertreatment plant and distribution pipes of a conventional steamgenerating system can be eliminated. Consequently, the use of vaporgenerator system 200 will significantly reduce the cost of extractingheavy oil from these oil fields.

Additionally, vapor generator system 200 can be used to force heat intooil fields where the oil is located in rock, shale or other difficultgeologic formations and at the end of the life cycle of an oil well oroil field. The process of heating the well or field reduces theviscosity for any oil or remaining oil that might be in rock, shale andor other geologic formations to allow for its pumping to the surface.Vapor generator system 200 will significantly reduce the cost ofproviding the heat necessary for production of oil in these situations.

Additionally, oil wells that are in production require maintenance. Thismaintenance includes the cleaning of oil and tar from the well pipingand is normally accomplished with steam or hot water. Vapor generatorsystem 200 will significantly reduce the cost of providing the heatnecessary for the maintenance of these wells.

INDUSTRIAL APPLICATIONS

Other industrial applications for vapor generator system 200 include:

Food preparation, including steam heat for cooking and baking, steam forcleaning and disinfection, steam and heat for pouching and or removingfruit and vegetable skins.

Providing steam and heat for cleaning and disinfection of meat andpoultry processing facilities.

Providing steam and heat for snow and ice removal from roads, sidewalks,driveways, walkways, roofs, heliports and aircraft runways. This snowand ice removal can be provided by mounting vapor generator system 200on a mobile vehicle, such as a snow plow.

Providing steam and heat for the desalinization of sea water (e.g., forevaporation or the generation of energy used in the desalinationprocess).

Providing steam and heat to generate electricity from turbines. FIG. 7is a block diagram illustrating an electrical generating system 700,which includes vapor generator system 200, turbine 701 and electricalgenerator 702. The high-temperature water vapor generated by vaporgenerator system 200 is used to rotate turbine 701. In response, turbine701 rotates conductive elements in electrical generator 702, therebycausing this generator 702 to generate electricity.

Providing steam and heat to power turbines for the purpose of chillingwater or glycol.

Providing steam and heat to provide energy for absorption chillers tochill water or glycol.

Providing steam and heat to preheat fuel in cold climates orapplications.

Providing steam and heat to systems that are used to provide warmth todivers and other underwater situations requiring protection from coldwater.

Providing steam and heat for industrial dryers or any industrial processthat requires heat for a drying process.

Providing steam and heat for sludge drying.

Providing steam and heat for curing various materials, i.e. carbonfiber, fiberglass, concrete.

Providing steam and heat for space heating and humidification.

Providing steam and heat for the lumber industry for kiln drying, barkstripping, cleaning and disinfection.

Providing steam and heat to strip paint and other coverings.

Providing steam and heat for distilling sprits.

Providing steam and heat for fractional distillation.

Providing steam and heat for cleaning and disinfection.

Providing steam and heat to clean rubber and other contaminants frommilitary and commercial aircraft runways.

Providing effluent pond heating for natural gas processing plants.

Providing heat to maintain the temperature of municipal effluent holdingand treatment ponds, thereby ensuring a continuous high level ofbiological degradation, especially in regions that experience extremeseasonal temperature changes.

Providing heat to the aggregate wash water at concrete batch plants.

Providing heat to log ponds and conditioning chests in plywood, veneer,orientated strand board (OSB), waferboard, chopstick plants.

Providing heat for protecting pulp and paper mill water intakeprotection against freezing, and white water solution heating.

Providing heat to barren solutions for ore extraction in heap leachmining operations.

Providing heat to barren brine solution to maximize solubility andrecovery of potash in flooded potash mines.

Providing heat for coal thawing for conveying.

Providing heating of bulk carpet and fabric dyes in carpet and fabricmanufacturing plants.

Providing heat for the evaporation of waste water to recover watertreatment chemicals in cogeneration plants with zero effluent discharge.

Providing heat for distillation or absorption in various industrialprocesses.

Environmental/Agricultural Applications

Some environmental/agricultural applications for vapor generator 100include:

Cleaning soil in and around underground petroleum storage tanks.

Providing steam and heat for the soil vapor extraction process.

Providing steam and heat for sewer and water treatment sludge drying.

Providing steam and heat for field disinfection.

Providing steam and heat for weed removal.

Providing steam and heat for drying and or disinfection of animalmanure.

Providing steam and heat for the conversion of organic waste to otherproducts. For example, green waste may be run through theabove-described soil remediation system (instead of contaminated soil),thereby greatly reducing the volume and weight of the resulting product.

Providing steam and heat for space heating and humidification of “hothouses” and other enclosed structures used to grow plants.

Providing steam and heat for heating of fields and orchards.

Providing steam and heat for the treatment of diseases of trees andother plants i.e. sudden oak death.

Medical Applications

Some medical applications for vapor generator 100 include:

Providing steam and heat for bulk sterilization of equipment.

Providing steam and heat for autoclaves.

Providing steam and heat for disinfection.

Providing steam and heat for cleaning of buildings, rooms and equipment.

Providing steam and heat for control of manufacturing processes, i.e.temperatures in fermentation and other processes.

Providing steam and heat for animal research facilities.

Commercial/Residential Applications

Some commercial/residential applications for vapor generator 100include:

Providing steam and heat for building heating and cooling systems.

Providing steam and heat for building hot water systems.

Providing steam and heat for building humidification systems.

Providing steam and heat for driveway, walkway and side walk heatingsystems.

Providing steam and heat for snow and ice removal.

Providing steam and heat for snow disposal.

Providing steam and heat for paint and wall paper removal.

Providing steam and heat for building cleaning and restoration.

Providing steam and heat for pressure and steam cleaning.

Providing steam and heat for building electrical cogeneration systems.

Although the invention has been described in connection with severalembodiments, it is understood that this invention is not limited to theembodiments disclosed, but is capable of various modifications, whichwould be apparent to one of ordinary skill in the art. Accordingly, thepresent invention is only limited by the following claims.

1. A method of extracting heavy oil, comprising: introducing water to acavity that surrounds a combustion chamber, wherein the water isintroduced at a location adjacent to a first end of the combustionchamber; removing water from the cavity at a location adjacent to asecond end of the combustion chamber, opposite the first end; routingthe water removed from the cavity into the combustion chamber at alocation adjacent to the first end of the combustion chamber;introducing fuel and air into the combustion chamber at the first end;igniting the fuel and air, thereby heating the water in the combustionchamber to create water vapor, and pre-heating the water in the cavitysurrounding the combustion chamber; routing the water vapor into aregion containing heavy oil, whereby the water vapor heats the heavyoil, thereby reducing the viscosity of the heavy oil; and thenextracting the heated heavy oil from the region.
 2. The method of claim1, further comprising forcing all combustion byproducts from thecombustion chamber into the region containing heavy oil.
 3. The methodof claim 1, further comprising positioning the combustion chamber suchthat the first end is located at a higher elevation than the second end.4. The method of claim 1, further comprising positioning the combustionchamber immediately adjacent to the region containing heavy oil.
 5. Themethod of claim 1, further comprising forcing the water into the cavity,out of the cavity and into the combustion chamber.
 6. The method ofclaim 1, further comprising introducing the air into the combustionchamber through a baffle.
 7. The method of claim 1, wherein the air isintroduced at a rate in the range of about 100 to 500 cubic feet perminute (cfpm) at a maximum pressure in the range of about 2 to 5pounds/square inch (psi).
 8. The method of claim 1, wherein the step ofigniting the fuel and air comprises continuously introducing sparks atthe first end of the combustion chamber.
 9. A heavy oil extractionsystem comprising: a combustion chamber having a first end and a secondend, located opposite the first end; means for initiating combustion atthe first end of the combustion chamber; an outer structure surroundingthe combustion chamber, wherein a cavity is located between thecombustion chamber and the outer structure; a water inlet located at theouter structure adjacent to the first end of the combustion chamber,wherein the water inlet is configured to receive water into the cavity;a water outlet located at the outer structure adjacent to the second endof the combustion chamber, wherein the water outlet is configured toreceive water from the cavity; a water injection element configured tointroduce water adjacent to the first end of the combustion chamber; anda water conduit coupling the water outlet to the water injectionelement, wherein the water conduit is configured to transfer water fromthe cavity to the water injector element; and a vapor outlet configuredto couple the second end of the combustion chamber to a region thatcontains heavy oil.
 10. The heavy oil extraction system of claim 9,further comprising means for holding the combustion chamber in anupright position, wherein the first end of the combustion chamber islocated at a higher elevation than the second end of the combustionchamber.
 11. The heavy oil extraction system of claim 9, furthercomprising means for positioning the combustion chamber immediatelyadjacent to the region containing heavy oil.
 12. The heavy oilextraction system of claim 9, further comprising a water pump coupled tothe water inlet, wherein the water pump regulates the flow of water intothe water inlet.
 13. The heavy oil extraction system of claim 9, whereinthe water injector element is configured to spray water into thecombustion chamber.
 14. The heavy oil extraction system of claim 9,wherein the means for initiating combustion comprise: an ignition sourcelocated in the combustion chamber adjacent to the first end; a fuelinlet configured to receive fuel into the combustion chamber adjacent tothe first end; and an air inlet configured to receive air at the firstend of the combustion chamber.
 15. The heavy oil extraction system ofclaim 14, further comprising a blower configured to force air into theair inlet.
 16. The heavy oil extraction system of claim 14, furthercomprising a baffle element coupled to the air inlet, wherein the baffleelement shields the ignition source and the fuel inlet from the airinlet.
 17. The heavy oil extraction system of claim 14, wherein theignition source and the fuel inlet are located on opposite sides of thecombustion chamber.
 18. The heavy oil extraction system of claim 14,wherein the ignition source comprises a spark plug.
 19. The heavy oilextraction system of claim 9, wherein the combustion chamber comprises afirst cylindrical element and the outer structure comprises a secondcylindrical element, wherein the cavity is located between the first andsecond cylindrical elements.
 20. The heavy oil extraction system ofclaim 19, wherein the first and second cylindrical elements are taperedat each end.